Download User Manual - Bacharach, Inc.

Fyrite INSIGHT
®
Combustion Gas Analyzer
(Siegert Version)
Instruction 0024-9461
Operation & Maintenance
Rev. 4 – October 2011
Product Leadership • Training • Service • Reliability
WARRANTY
Bacharach, Inc. warrants to Buyer that at the time of delivery this Product will be free from defects in mater­ial
and manufac­ture and will conform substan­tially to Bacharach Inc.’s ap­plicable specifications. Bacharach’s
liability and Buyer’s remedy under this warranty are limited to the repair or replacement, at Bacharach’s option,
of this Product or parts thereof returned to Seller at the factory of manufac­ture and shown to Bacharach Inc.’s
reasonable satisfaction to have been defective; provided that written notice of the defect shall have been given
by Buyer to Bacharach Inc. within two (2) years after the date of delivery on Product and all gas sensors except
the O2 sensor which has a one (1) year warranty by Bacharach, Inc.
Bacharach, Inc. warrants to Buyer that it will convey good title to this Product. Bacharach’s liability and Buyer’s
remedy under this warranty of title are limited to the removal of any title defects or, at the election of Bacha­rach,
to the replacement of this Product or parts thereof that are defective in title.
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED IN LIEU OF (I) ANY
AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHAN­TABILITY AND FITNESS FOR A PARTICULAR PURPOSE: AND (II) ANY
OBLIGA­TION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTRACT OR TORT, WHETHER OR NOT ARISING FROM BACH­A­RACH’S NEGLIGENCE, ACTUAL OR IMPLIED. The remedies of the Buyer shall be limited
to those provided herein to the exclusion of any and all other remedies includ­ing, without limita­tion incidental or
consequen­tial damages. No agree­ment varying or extending the foregoing warranties, remedies or this limitation will be binding upon Bacharach, Inc. unless in writing, signed by a duly authorized officer of Bacharach.
Register your warranty by visiting www.MyBacharach.com.
NOTICE
Product improvements and enhancements are continuous, therefore the specifications and information
­contained in this document may change without notice.
Bacharach, Inc. shall not be liable for errors contained herein or for incidental or consequential damages in
­connection with the furnishing, performance, or use of this material.
No part of this document may be photocopied, reproduced, or translated to another language without the prior
written consent of Bacharach, Inc.
Copyright © 2002–2011, Bacharach, Inc., all rights reserved.
BACHARACH and Fyrite are registered trademarks of Bacharach, Inc. B-SMART is a trademark of Bacharach,
Inc. All other trademarks, trade names, service marks and logos referenced herein belong to their respective
companies.
A
Contents
1.0 INTRODUCTION.............................................................................1
®
1.1 The Fyrite INSIGHT..........................................................................1
®
1.2 Fyrite INSIGHT Features & Benefits..................................................2
1.3 Operational Overview.........................................................................5
2.0 Technical Characteristics................................................6
3.0 SETTING UP THE ANALYZER.......................................................8
3.1 Preliminary Steps...............................................................................8
3.2 Power.................................................................................................8
3.2.1 Installing or Replacing Batteries........................................................8
3.2.2 Using the AC Power Adapter............................................................ 8
3.3 Connecting the Probe Hose & Thermocouple.....................................8
3.4 Front Panel Push Buttons................................................................ 11
3.5 Power-Up & Run/Hold Screen Overview.........................................12
3.6 Setup Mode......................................................................................13
3.7 Setup Menu......................................................................................14
3.7.1 Temperature Units...........................................................................14
3.7.2 Pressure Units.................................................................................15
3.7.3 Smoke Number...............................................................................15
3.7.4 Oil Derivative...................................................................................16
3.7.5 Boiler Temperature..........................................................................17
3.7.6 Clock...............................................................................................17
3.7.7 O2 Reference..................................................................................18
3.7.8 Print Pressure.................................................................................18
3.7.9 Zoom...............................................................................................19
3.7.10 Username......................................................................................20
3.7.11 Run/Hold Format...........................................................................21
3.7.12 Language Selection......................................................................24
3.7.13 Button Sound................................................................................25
3.7.14 CAL Reminder Period...................................................................25
3.7.15 Inactivity Timeout..........................................................................26
3.7.16 Post-Purge Period.........................................................................27
3.7.17 Auto/Manual Zero Feature............................................................28
4.0 Operation.................................................................................30
4.1
4.2
4.3
4.4
4.5
4.6
Operating Tips...................................................................................30
Analyzer Power On & Warm Up........................................................31
Fuel Selection ..................................................................................31
Sampling Point .................................................................................32
Performing a Combustion Test..........................................................35
Making a Draft/Pressure Measurement............................................36
i
4.7 Temperature Measurement...............................................................38
4.8 Saving Test Data...............................................................................38
4.9 Ending a Combustion Test................................................................39
4.10 Emptying the Water Trap.................................................................39
4.11 Powering Off the Analyzer & Purging..............................................40
4.12 Low Battery Alarm...........................................................................40
4.13 Memory...........................................................................................40
4.13.1 Averaging Stored Test Data . ........................................................41
4.14 Printing Test Data............................................................................43
®
4.15 Fyrite User Software.......................................................................44
5.0 CALIBRATION & MAINTENANCE...............................................45
5.1 B-Smart™ Sensors..........................................................................45
5.2
5.3
5.4
5.5
5.6
5.7
Starting a Calibration.........................................................................45
B-Smart™Sensor Replacement & Calibration.................................47
Pressure Sensor Calibration ............................................................47
T-Stack Calibration............................................................................49
T-Air Calibration.................................................................................51
CO Sensor Calibration .....................................................................53
6.0 Maintenance............................................................................55
®
6.1 Fyrite INSIGHT Disassembly............................................................55
6.2 Water Trap / Filter . ...........................................................................57
6.2.1 Emptying the Water Trap Chamber.................................................57
6.2.2 Replacing the Filter Element...........................................................57
6.3 O2 & CO Sensor Replacement..........................................................58
6.3.1 O2 Sensor.......................................................................................58
6.3.2 CO Sensor.....................................................................................59
6.4 Thermocouple Replacement.............................................................60
6.5 Gas Pump Replacement...................................................................61
6.6 Cleaning the Probe...........................................................................63
6.7 Error Messages.................................................................................64
6.8 Diagnostics Screen...........................................................................65
6.9 Status Screen....................................................................................66
7.0 PARTS & SERVICE......................................................................68
7.1 Replacement Parts...........................................................................68
7.2 Accessories......................................................................................69
7.3 Service Centers................................................................................69
8.0 DECLARATION OF CONFORMITY.............................................70
Appendix A- Formulas & Tables..............................................71
ii
Fyrite INSIGHT
1.0INTRODUCTION
1.1 The Fyrite® INSIGHT
The Fyrite® INSIGHT is a hand-held residential and commercial grade
portable combustion analyzer that is designed for on-demand sampling of
light industrial combustion equipment, residential furnaces, and appliances.
The following conventions are used in this manual:
WARNING: A warning statement denotes a potential hazard
associated with the use of this equipment. Failure to follow this
information could result in serious personal injury or death.
CAUTION: A caution statement indicates a potentially hazardous
situation which, if not avoided, may result in minor or moderate injury. Caution statements may also be used to alert against unsafe
practices.
To assure operator safety and the proper use of the Fyrite INSIGHT,
please read the contents of this manual for important information on the
operation and maintenance of the analyzer. This manual contains information on all models of the Fyrite INSIGHT. Please disregard any information that does not pertain to your model.
WARNINGS!
• This analyzer should not be used on a continuous basis.
• This analyzer should not be used as a safety device.
• Except for sensor and battery replacement, this analyzer should only be
opened and serviced by authorized personnel.
• When testing an appliance, a full visual inspection of the appliance
should be carried out to ensure its safe operation.
• HAZARDOUS AREA WARNING: This instrument has not been designed to be intrinsically safe for use in areas classified as hazardous
locations. For your safety, DO NOT use it in hazardous (classified) locations.
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Fyrite INSIGHT
CAUTIONS!
• When the instrument is used in an inefficient furnace or boiler
application where there is a high emission of soot, probe sample
filter may become clogged. Check filter before every use to confirm
that it is clean for use or replace with a new filter. To prevent this
from occurring, a smoke test should be performed before operating
under such conditions to ensure that the furnace is burning at a level
appropriate for the use of this instrument.
• Use only the Bacharach AC Adapter. Failure to do so could result in
damage to the unit and void the warranty.
• Do not store instrument or its sensors with solvents or products that
contain solvents.
1.2 Fyrite® INSIGHT Features & Benefits
AUTO/MANUAL ZERO - In automatic mode, the instrument automatically zeroes all sensing channels on ambient air when it is powered on. If
a particular sensor is in error during warm-up, the instrument automatically displays the error and continues to operate with the sensor in error. However, all information dependent on the sensor in error will not
be presented. When the CO channel is set to manual zero, the analyzer
does not zero the CO sensor to ambient conditions during start up. In this
mode, the “fresh air zero” established during manual mode setup is stored
in memory and used during the measurement of CO.
TEMPERATURE UNITS - Temperatures can be displayed in Centigrade
or Fahrenheit.
PRESSURE UNITS - Pressures can be displayed in milliBar (mB),
Pascal (Pa), hectoPascal (hPa), Millimeters of Water Column (mmwc), or
Inches of Water Column (inwc).
LANGUAGE - The display options are English, French, Spanish, German,
Italian, Danish, Polish and Dutch.
MEMORY - The Fyrite® INSIGHT has the ability to store, recall to
display, and print a minimum of 100 sets of time and date coded combustion, differential pressure, or differential temperature test records. This
includes manually entered Smoke Numbers, Oil Derivatives, and Boiler
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Fyrite INSIGHT
Temperatures.
AVERAGING - The Fyrite® INSIGHT can average 3 like records and
print out the information.
DOWNLOAD - Test records can be downloaded to a personal computer via
the USB port. Saved records are transferred using PC based software and
will be automatically loaded into an Excel spreadsheet. PC based software
will also have the capability to update the instrument time and date and
upload custom fuels, username, customer logo, and future code updates.
The INSIGHT can also be set up from PC software.
USER INFORMATION - The instrument will accept up to three lines of
20 characters of user information. This information will appear with the
test records when they are printed or downloaded.
CALIBRATION - Calibration can be performed by applying gas and entering calibration gas concentrations through software menu selections.
SMART SENSORS - B-Smart sensor technology is employed for the CO
channel. CO sensors are calibrated prior to shipment and provide data that
can be entered through the software menu selections for easy calibration
without applying gas.
CALIBRATION REMINDERS - Calibration reminders can be set for
Never, 6, 8, 10, 12, or 15 months.
DISPLAY FORMAT - The Run/Hold display format can be presented in
default or custom ordered for specific needs. Up to 8 lines can be customized in the Run/Hold screen.
DISPLAY ZOOM - Combustion test data in the Run/Hold screens can be
shown with enlarged characters to make viewing easier. The complete
list of Run/Hold data can be scrolled through for all zoom levels. Available
zoom levels and information display are as follows:
• Standard - 4 lines of information
• 2X - 3 lines of enlarged characters
• 3X - 2 lines of enlarged characters
STATUS - A status menu displays the instrument software version, boot
version, model number, and serial number.
DIAGNOSTICS - The diagnostics menu displays the O2 sensor life, CO
sensor information, and hours of operation for the instrument and the
pump.
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Fyrite INSIGHT
KEYPAD SOUND - Keypad sounds can be enabled or disabled with software menu selections.
LOW BATTERY - A tone will sound every 10 seconds when a low battery
condition exists. A low battery message will also be displayed.
AUTOMATIC POWER DOWN - The instrument can be set to automatically power off after a period of inactivity unless the user presses any
button; the CO is greater than 50 ppm, or the O2 is less than 16.0%. Automatic power down can be set for None, 30, or 60 minutes.
PURGE - The sensors will be purged when the instrument is shutdown
until sensor outputs indicate that they have been exposed to fresh air.
Pressing the On/Off key a seconds time can defeat the purge routine. The
minimum purge time can be set to None, 5 seconds, 1, 5, or 10 minutes.
SENSOR ACCESS - Sensor replacement can be accomplished in the field.
Easy access to the O2 and CO sensors is provided through the back of the
instrument.
POWER - The Fyrite® INSIGHT is powered by 4 AA alkaline batteries. A
new set of alkaline batteries will provide a minimum of 20 hours of continuous operation with the pump running and the back light on. Optionally, the analyzer can operate with a universal AC adapter. When the AC
adapter is plugged into the unit, batteries do not have to be removed.
PRINT MEMORY RANGE FEATURE - The print memory function permits the printing of a range of memory locations (versus printing the value
of a single memory location). To access this feature, press F2 then Memory
then Print Multiple.
INSIGHT
INSIGHT
Kit
0024-8252
0024-8253
Hard Carry Case
X
X
Probe Assembly
X
X
Printer IRDA
X
Boot
X
X
PC Software
X
X
USB Cable
X
X
Batteries
X
X
Features Matrix for Models 0024-8252 and 0024-8253
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Fyrite INSIGHT
1.3 Operational Overview
Pressing the PWR button turns the analyzer ON. Note that there is a
warm-up period of 60 seconds that must elapse before the analyzer can be
used.
To perform a combustion test, choose a fuel code that corresponds to the
fuel being burned by the appliance being tested (Section 4.3), and then
press the RUN/HOLD button to place the analyzer into its Run Mode.
­Begin testing by inserting the analyzer’s probe tube into the flue-gas
stream of the appliance under test. The analyzer will monitor the flue gas
and display measured and calculated values that are relative to the combustion process. These values are displayed on the analyzer’s LCD, and
are chosen for display by pressing the Increment (▲) and Decrement (▼)
buttons. The recommended time required to achieve a stable measurement
is a minimum of 3 minutes.
Pressing the RUN/hold button during a test will freeze all measured and
calculated values at their current levels. Pressing the RUN/HOLD button
again resumes testing.
A backlight enables an operator to read the display in dimly-lit areas.
Pressing the PWR button turns the backlight ON and OFF.
An optional power saver function will shut the analyzer OFF after a set
time period of inactivity. This feature is disabled if the CO value is greater
than 50 ppm or the O2 value is less than 16.0%.
Press the PWR button for at least two seconds to power the analyzer
OFF. Note that there is a 5 second delay before the analyzer actually
turns OFF, during which time the unit can be kept ON by pressing the
RUN/HOLD button. There is a CO purge feature that keeps the analyzer’s
pump running until the measured CO level drops below 50 ppm.
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Fyrite INSIGHT
2.0 Technical Characteristics
The Analyzer Measures & Displays:
Oxygen
0.1 to 20.9% O2
Carbon Monoxide
0 to 2000 ppm
Stack Temperature
-20 to 650 °C (-4 to 1202 °F)
Primary/Ambient Air Temperature
-20 to 316°C (-4 to 600 °F) CO
Differential Pressure/Draft
+ 249 mB (± 100 inwc)
The Analyzer Computes & Displays:
qA
0.1 to 100%
ETA
0.1 to 111.2%
EFF
0.1 to 100 %
CO/CO2 Ratio
0.0001 to a fuel dependent
maximum value in %
Carbon Dioxide
0.1 to a fuel dependent ­
maximum value in %
CO referenced to %O2
0 to 9,999 ppm
LAMBDA
1 to 9.95%
Fuel Selection:
• Natural Gas
• LEG
• Oil #2
• Oil #6
• KOKS
• Propane
• Coal
• Biofuel
• LPG
• Butane
Normal Operating Conditions:
Temperature
• Analyzer
• Probe
Humidity
Dimensions
20.1 cm (7.9 in) Height
9.1 cm (3.6 in) Width
5.8 cm (2.3 in) Depth
6
0 to 40 °C (32 to 104 °F)
538 °C max (1,000 °F) at
5" insertion
15 to 90% RH, Non-Condensing
Weight
0.45 kg (1 lb.)
Fyrite INSIGHT
General Characteristics:
Power Requirements
Four disposable ‘AA’ Alkaline batteries (optional AC adapter is available)
Operating Time
Minimum of 20 hours continuous operation
(pump running and backlight ON)
Warm Up Time
60 seconds
Memory
Up to 100 complete sets of
combustion, temperature, & pressure
tests can be saved in memory.
Display
128 x 64, LCD Graphic Display
Front Panel Controls
Eleven front panel push buttons
(Refer to Section 3.4)
Interfaces
IrDA printer & USB connectivity
Accuracy:
Oxygen
±0.3% O2 with a typical flue gas
concentration of CO2
Carbon Monoxide
±5% of reading or ±10 ppm, whichever is
greater*, in the range of 0 to 1000 ppm.
Flue Gas Temperature
±2 °C between 0 & 124 °C
(±4 °F between 32 & 255 °F)
±3 °C between 125 & 249 °C
(±6 °F between 256 & 480 °F)
±4 °C between 250 & 400 °C
(±8 °F between 481 & 752 °F)
Ambient/Primary
Temperature
±1 °C between 0 & 100 °C
(±2 °F between 32 & 212 °F)
Draft
±2% of reading or ±0.05 mB, whichever is greater
in the range of -25 to +25 mB
± 3% in the range of -25 to -100 mB
± 3% in the range of 25 to 100 mB
* Tighter CO accuracy in the lower ranges, up to ±2 ppm, may be
attained if a lower range calibration gas (e.g. 100 ppm CO) is used.
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Fyrite INSIGHT
3.0 SETTING UP THE ANALYZER
3.1 Preliminary Steps
Before using the analyzer . . .
•Check batteries
•Connect probe to analyzer
•Check setup
(Section 3.2)
(Section 3.3)
(Section 3.6)
3.2 Power
3.2.1 Installing or Replacing Batteries
Install fresh batteries as described below. Check the analyzer for sufficient
charge prior to each use. Replace the batteries if the low-battery symbol
appears in the upper right corner of the screen. To replace the batteries:
1. Remove battery cover from back of analyzer.
2. If old batteries are installed, remove them and properly discard.
3. Observing the polarity markings inside the battery compartment,
install four ‘AA’ Alkaline batteries.
4. Replace battery cover.
3.2.2 Using the AC Power Adapter
The optional AC power adapter is capable of powering the analyzer on a
continuous basis. The adapter plugs into an appropriate 100-240 VAC,
50/60 Hz wall outlet and produces an output of +5 VDC. The adapter’s
output connector plugs into the analyzer’s POWER jack located on the bottom of the unit. The batteries do not need to be removed when using the
AC adapter.
CAUTION: Use only the Bacharach AC Adapter (P/N 24-1254). Failure to do so could damage the unit and will void the warranty.
3.3 Connecting the Probe Hose & Thermocouple
A rigid stainless steel probe with handle is connected to a flexible hose
with integral water-trap / filter used to draw a gas sample into the analyzer from the room, grilles, diffusers, and furnace flues.
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Fyrite INSIGHT
Inspect the flue-gas hose for cracks. If a hose is defective, replace the entire
probe assembly.
Before using the analyzer, check that the Water Trap / Filter is dry and
not dirty. If necessary, dry out the trap and replace the filter element per
Section 6.2.
Perform the following steps to connect the probe assembly to the Fyrite
INSIGHT:
1. Push the probe’s sample-gas hose onto the GAS inlet fitting.
2. Push the probe’s draft hose onto the “+” pressure fitting.
3. Push the probe’s thermocouple into the T-STACK jack
IMPORTANT: DO NOT force the thermocouple connector
into its jack. The connection tabs are different sizes, allowing the connector to fit in only one way.
4. Push the optional ambient/primary-air thermocouple into the T-AIR
jack.
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Fyrite INSIGHT
Fyrite® INSIGHT Connectors
USB Cable
AC Power
Adapter Jack
(Power)
Primary Ambient
Air Thermocouple
(T-Air) (Optional)
Differential
Pressure Hose
(Optional)
Draft
Hose
Sample Gas
Hose
Sample Gas
Thermocouple
Connector (T-Stack)
Probe
Tube
Probe
Stop
Water Trap/
Filter Assembly
Probe
Handle
Fig. 3.1
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Fyrite INSIGHT
3.4
Front Panel Push Buttons
Note that a push button may perform several functions,
depending on the analyzer’s model number and the
screen that is displayed.
• Pressing function keys accepts the corresponding function
defined at the bottom of the display, including PRINT, SAVE,
MENU, differential pressure ZERO, differential temperature
ZERO, PAGE UP, PAGE DOWN and CLEAR data.
• Scrolls up, down, left, and right through the display screen
options.
• Up and Down arrows cause the displayed value to increase or decrease correspondingly.
• Acts as an ENTER button. Performs the action selected.
• While in the HOLD screen, turns the sample pump on, displays the RUN screen, and begins a combustion test.
• While in the RUN screen, turns the sample pump off, displays the
HOLD screen and the last set of combustion data.
• Displays the HOLD screen while pressing it from most menus.
• Return the display to the HOLD screen while pressing it during the
5 second power down sequence.
• Cancels most operations and displays the previous screen.
• Powers the analyzer ON and OFF. Hold this button down for
at least 2 seconds to turn the power OFF.
• Toggles the backlight ON and OFF while the analyzer is
turned ON.
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Fyrite INSIGHT
3.5 Power-Up & Run/Hold Screen Overview
Version: V2.00
Model: 0024- 8252
Serial:
NW1060
Press the PWR button to power up the analyzer.
Information about the device’s software version,
model number and serial number will be displayed briefly.
A warm up screen, displaying a 60 second countdown, will then appear.
After the countdown, the Run/Hold screen will
appear in Hold mode. This screen displays a list
of information relative to the combustion process.
The ▲▼ up/down arrow keys permit scrolling
through the list, as displayed in the illustration.
▲▼
NOTE:
The following sections, 3.6 Setup Mode and
3.7 Setup Menu, explain how to access Setup
menus and how to make modifications to preset
parameters.
If you wish to use the analyzer without making
setup modifications, go to section 4.0 Operation.
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Fyrite INSIGHT
3.6 Setup Mode
The analyzer is preset at the factory with the parameters displayed below,
but can be modified as described in their corresponding sections.
Function
Parameter
To modify, refer to:
Fuel
Natural Gas
Section 4.3
Temperature Unit
°C
Section 3.7.1
Pressure Unit
mB
Section 3.7.2
Clock
Not Initialized
Section 3.7.6
O2 Reference
0%
Section 3.7.7
Zoom
Standard
Section 3.7.9
Language
English
Section 3.7.12
Button Sound
On
Section 3.7.13
CAL Reminder
Never
Section 3.7.14
Inactivity Timeout
None
Section 3.7.15
Post-Purge Period
None
Section 3.7.16
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Fyrite INSIGHT
• Press ▲▼ buttons to scroll/highlight options.
• Press
(ENTER) to select or save.
• Press ESC to go back.
3.7 The Setup Menu
1. Press the MENU (F2) button to access the Main Menu.
2. Scroll to Setup. Press ENTER.
Fuel
Pressure
Temperature
Memory
▲▼
Setup
Calibration
Diagnostics
Status
3.7.1 Temperature Units
Use this menu to display temperature in ºC or ºF.
1. Access the Setup Menu per Section 3.7
2. Select Temperature Units.
3.Press Enter to access the Temperature Units menu. Select the
desired temperature unit.
4. Press ENTER to save and return to the Setup Menu. Press ESC to
cancel.
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Fyrite INSIGHT
• Press ▲▼ buttons to scroll/highlight options.
• Press
(ENTER) to select or save.
• Press ESC to go back.
3.7.2 Pressure Units
Select to display pressure in inches of water column (inwc), millibar (mb),
Pascals (Pa), hectoPascals (hPa), or millimeter of water column (mmwc) as
follows:
1. Access the Setup Menu per Section 3.7.
2. Select Pressure Units.
3. The Pressure Units Menu will be displayed.
4. Select the desired pressure unit from the list.
5. Save and return to the Setup Menu or press ESC to cancel.
3.7.3 Smoke Number
Three smoke numbers, as measured by the Bacharach True Spot Smoke
tester, can be manually entered into the analyzer and their average automatically calculated. The average smoke number will be displayed on the
combustion test Run/Hold screen. Enter smoke numbers as follows:
1. Access the Setup Menu per Section 3.7 .
2. Select Smoke Number.
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Fyrite INSIGHT
• Press ▲▼ buttons to scroll/highlight options.
• Press
(ENTER) to select or save.
• Press ESC to go back.
3. Use the ◄► buttons to enter the desired smoke number for the options in the list.
4. Save and return to the Setup Menu or press ESC to cancel.
3.7.4 Oil Derivative
Use the Oil Derivatives screen to manually enter Yes or No in response to
if oil derivatives were present during the smoke test. Oil derivatives will be
displayed on the combustion test Run/Hold screen. Enter an oil derivative
as follows:
1. Access the Setup Menu per Section 3.7 .
2. Select Oil Derivative.
3. Select Yes or No.
4. Save and return to the Setup Menu or press ESC to cancel.
16
Fyrite INSIGHT
• Press ▲▼ buttons to scroll/highlight options.
• Press
(ENTER) to select or save.
• Press ESC to go back.
3.7.5 Boiler Temperature
Use the Boiler Temperature screen to manually enter a boiler temperature
as measured by an external thermocouple. Boiler temperature information
will be displayed on the combustion test Run/Hold screen . Enter the boiler
temperature as follows:
1. Access the Setup Menu per Section 3.7.
2. Select Boiler Temperature.
4. Use the ◄► buttons to move the cursor. Use the ▲▼ buttons to
increment and decrement the number value.
5. Save and return to the Setup Menu or press ESC to cancel.
3.7.6 Clock
The Set Clock screen permits entry of time and date.
1. Access the Setup Menu per Section 3.7.
2. Select Clock.
3. Select numbers for the current date and time. Use the ◄► buttons
to move the cursor.
17
Fyrite INSIGHT
• Press ▲▼ buttons to scroll/highlight options.
• Press
(ENTER) to select or save.
• Press ESC to go back.
4. Save and return to the Setup Menu or press ESC to cancel.
3.7.7 O2 Reference
The measured value of CO can be referenced to a specific O2 percentage of
0% to 15%. Set up the reference value as follows:
1. Access the Setup Menu per Section 3.7.
2. Select O2 Reference.
3. Select the O2 reference value. Range: 0-15.
4. Save and return to the Setup Menu or use ESC to cancel.
3.7.8 Print Pressure
Select whether to print or not print the pressure measurement on the combustion test printout as follows:
1. Access the Setup Menu per Section 3.7.
2. Select Print Pressure.
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Fyrite INSIGHT
• Press ▲▼ buttons to scroll/highlight options.
• Press
(ENTER) to select or save.
• Press ESC to go back.
3. Select Yes or No in regard to printing the pressure measurement.
4. Save and return to the Setup Menu or use ESC to cancel.
3.7.9 Zoom
Combustion test data in the Run/Hold screen can be shown with enlarged
characters to make viewing easier. The operator can set zoom levels to
Standard, 2X or 3X. The Standard zoom setting will display 4 lines of
combustion test data at one time; 2X will display 3 lines of data with enlarged characters; 3X will display 2 lines of data with enlarged characters.
The operator can scroll through the complete list of measured and calculated data no matter what zoom level has been selected. Select the desired
zoom level as follows:
1. Access the Setup Menu per Section 3.7.
2. Select Zoom.
3. Select the desired zoom level.
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Fyrite INSIGHT
• Press ▲▼ buttons to scroll/highlight options.
• Press
(ENTER) to select or save.
• Press ESC to go back.
4. Save and return to the Setup Menu or use ESC to cancel.
3.7.10 Username
The name of the user or owner (e.g. company name, address, phone number) can be stored in system memory. Up to three lines of text may be
entered. Each line may contain up to 20 alphanumeric and symbol characters. This information will appear at the top of each printout until it is
cleared or new information is entered.
Username information entry:
1. Access the Setup Menu per Section 3.7.
2. Select Username. The Edit Username screen will display with the
first line highlighted.
3. Press ENTER. Only the first character space will be highlighted.
Use the ▲▼ buttons to make selections for each character space.
When the ▲▼ buttons are pressed, symbols (/,#,&, etc.) display first. The ▲▼ keys
permit continuous scrolling in either direction to access the other options. Press and
hold the ▲▼ buttons for rapid scrolling.
Lower
case
Symbols
Upper
case
Numbers
4. Use the ◄► buttons to move the cursor to the next space. When a line is
completed, press the ENTER key to confirm, then use the ▲▼ buttons to navigate to another line, if desired.
20
Fyrite INSIGHT
• Press ▲▼ buttons to scroll/highlight options.
• Press
(ENTER) to select or save.
• Press ESC to go back.
5. Save the information by selecting Edit Complete.
Clearing a Username:
The CLEAR option will appear (above the F3 button) when an
entire line is selected. To delete all characters on the line, press F3
while the line is highlighted.
6. Repeat Steps 3-5 to edit remaining lines.
7. When all input is completed, select Edit Complete or ESC to cancel the edits and return to the Setup Menu.
Helpful Hint: Use the Fyrite® user software to upload this information from your computer.
3.7.11 Run/Hold Format
Fyrite INSIGHT test data is displayed on the Run/Hold screen. The
Run/Hold button is used to toggle between Run and Hold.
Press the Run/Hold button to start the pump. While it is running, the
word Run will appear in the upper-left corner of the display. The instrument continuously measures and calculates the data displayed in the Run/
Hold screen.
When the RUN/HOLD button is pressed again, the pump will stop. The
word Hold will appear in the upper-left corner of the display. The instrument will now show the last measured and calculated data taken before
the instrument was placed in Hold. Use the ▲▼ buttons to scroll through
the complete list of measured and calculated values when in RUN or in the
HOLD mode.
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• Press ▲▼ buttons to scroll/highlight options.
• Press
(ENTER) to select or save.
• Press ESC to go back.
The default order in which data is displayed is listed below.
O2 CO
LAMBDA
CO2
CO2Max
T-STK
T-AIR
qA
Eta
Eff
CO/CO2
CO(n)
AVG SMOKE
OIL DERIVE
=
=
=
=
=
=
=
=
=
=
=
=
=
=
BOILER TEMP =
Oxygen
Carbon Monoxide
Excess air
Carbon Dioxide
% CO2 in flue gas assuming perfect combustion
Stack Temperature
Ambient/Primary Air Temperature
Stack loss
Efficiency referenced to the lower heating value
Efficiency referenced to the higher heating value
Carbon Monoxide/Carbon Dioxide
Carbon Monoxide content referenced to % O2
Average of 3 manually entered smoke numbers
Manually entered Yes or No
Boiler temperature manually entered
NOTE: (n) is the current O2 Reference selected.
Changing the data display order:
1. Access the Setup Menu per Section 3.7.
2. Select Run/Hold Format.
A screen will appear that displays the Edit Format and Reset Format options.
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Fyrite INSIGHT
• Press ▲▼ buttons to scroll/highlight options.
• Press
(ENTER) to select or save.
• Press ESC to go back.
3. Select to display the current format.
4. Scroll to the item in the list to be modified and press the ENTER
button. The cursor will begin to flash.
5. With each press of the ▲▼ buttons, another option from the data list
will be displayed within the flashing cursor field. Scroll through the
options and select the desired data to appear in that location.
6. Press ENTER to save the selection. The cursor will stop flashing.
7. Change the data displayed at other locations by repeating steps 4
through 6.
8. When finished, scroll to the bottom of the list to select Edit Complete.
9. Press ENTER to save the new display format and return to the Edit
Format or Reset Format option screen.
Resetting Display Format to Factory Default Settings
1. Access the Setup Menu per Section 3.7.
2. Select Run/Hold Format.
A screen will appear that displays the Edit Format and Reset Format options.
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Fyrite INSIGHT
• Press ▲▼ buttons to scroll/highlight options.
• Press
(ENTER) to select or save.
• Press ESC to go back.
3. Select Reset Format.
4. Select Yes. Press the ENTER button to reset the format and return
to the Run/Hold format options.
5. Press ESC to go to the Setup Menu.
3.7.12 Language Selection
The display screen text can be in English, French, Spanish, German, Italian, Danish, Polish or Dutch.
Select the desired language as follows:
1. Access the Setup Menu per Section 3.7.
2. Select Language Selection.
A screen will appear that displays the language options.
3. Scroll through the list and select the desired language.
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Fyrite INSIGHT
• Press ▲▼ buttons to scroll/highlight options.
• Press
(ENTER) to select or save.
• Press ESC to go back.
4. Press ENTER to activate the selection and return to the Setup Menu
or press ESC to cancel.
3.7.13 Button Sound
The audible sound used to signal when a button is pressed can be turned
OFF and ON as follows:
1. Access the Setup Menu per Section 3.7.
2. Select Button Sound.
3. Select Off or On.
4. Press ENTER to save the selection and return to the Setup Menu or
ESC to cancel.
3.7.14 CAL Reminder Period
The analyzer can be set to indicate a calibration reminder during the 60
second warm-up. Calibration reminders can be preset to occur: Never, 6,
8, 10, 12, or 15 months after the last calibration. When the preset period
is exceeded, the instrument will display the reminder and how long it has
been since the sensors were last calibrated. If a calibration reminder is
displayed, the operator can press the RUN/HOLD key to go to the Run/Hold
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Fyrite INSIGHT
• Press ▲▼ buttons to scroll/highlight options.
• Press
(ENTER) to select or save.
• Press ESC to go back.
Screen for normal operation. Regular calibration periods of 6 months to 1
year are recommended.
NOTE: The default CAL Reminder period is Never. Set the calibration reminder period as follows:
1. Enter the Setup Menu per Section 3.7.
2. Select CAL Reminder Period.
3. Select the desired time period.
4. Press ENTER to save selection and return to the Setup Menu or ESC
to cancel.
NOTE: The date and time settings must be correct to get accurate calibration reminders.
3.7.15 Inactivity Timeout
This is the selected amount of time that will elapse before the analyzer
automatically powers down due to inactivity from the user. The timeout
periods available are: None, 30 or 60 minutes. However, if the CO value
is greater than 50 ppm or the O2 value is less than 16.0%, this feature is
disabled and power down will not occur.
NOTE: The default set time is None. This selection will prevent the
analyzer from automatically powering off.
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• Press ▲▼ buttons to scroll/highlight options.
• Press
(ENTER) to select or save.
• Press ESC to go back.
Set the Inactivity Timeout Period as follows:
1. Access the Setup Menu per Section 3.7.
2. Select Inactivity Timeout.
3. Select the desired timeout period.
4. Save the selection and return to the Setup Menu or ESC to cancel.
3.7.16 Post-Purge Period
The analyzer can be setup to purge the sensors following the combustion
test. It can be programmed to purge for None, 5 seconds, 1, 5, or 10 minutes.
Set the Post-Purge Period as follows:
1. Access the Setup Menu per Section 3.7.
2. Select Post-Purge Period.
3. Select the desired time period.
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Fyrite INSIGHT
• Press ▲▼ buttons to scroll/highlight options.
• Press
(ENTER) to select or save.
• Press ESC to go back.
4. Save the selection and return to the Setup Menu or ESC to cancel.
3.7.17 Auto/Manual Zero Feature
Manual Zero: When the CO channel is set to
manual zero, the analyzer does not zero the CO
sensor to ambient conditions during start up. In
this mode, the “fresh air zero” established during
manual mode setup is stored in memory and used
during the measurement of CO.
Auto Zero: When the CO channel is set to auto
zero, the CO sensor is zeroed to the ambient CO
level during start up.
IMPORTANT: When using this mode, the analyzer must be
turned ON in fresh air; otherwise, incorrect CO readings will
occur.
Auto Zero determines the zero reading of the CO channel in fresh air and
provides an offset for the CO measurements. Manual zero is used to detect
CO that may be present during start-up. The auto/manual zeroing option
allows the operator to select the start-up mode. It is selectable from the
CO Zero Setting of the Setup Menu.
1. From the SETUP MENU, use the ▲▼ buttons to highlight CO Zero
Setting, and then press ENT to display the CO ZERO SETTING
MENU.
2. Use the ▲▼ buttons to highlight the desired option (Manual or Auto
Zero), and press ENT to save the selection and re-display the SETUP
MENU.
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Fyrite INSIGHT
Both methods take the user through a 60-second count down to establish
a new zero. The manual mode establishes a fresh air zero and stores it for
use during instrument startup.
Auto-Zero versus Manual Zero
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4.0 Operation
4.1 Operating Tips
• When an analyzer is brought in from a cold vehicle, let it warm up
slowly to minimize condensation. Temperatures below freezing will not
damage the analyzer; however, bringing a cold analyzer into a warm,
humid environment may cause condensation to form inside the case.
Caution: Although the analyzer itself is not damaged by an extremely cold environment, the electrochemical sensors may be
damaged. The O2 sensor’s electrolyte will freeze at approximately
-25 °C and the CO sensor’s at approximately -70 °C. If the analyzer
is exposed to an extremely cold condition, it is strongly suggested
that the sensor housings be examined for hairline cracks. Be aware
that a leaking sensor can cause chemical burns to the skin and
possibly damage the PCB assemblies.
• Ensure that the analyzer is sampling fresh air when turned ON. Pulling
a stack-gas sample through the analyzer during its warm-up period will
not damage the analyzer, but it will result in incorrect sensor readings,
and may result in sensor error messages appearing after the warm-up
cycle completes.
• Note that flue-gas condensate is acidic and very corrosive. It is important
not to allow the analyzer’s internal components to come in contact with
condensate for long periods of time.
• Before each use, inspect the filter element of the water-trap / filter assembly. Replace the filter if it looks dirty.
• When sampling flue-gas, keep the analyzer above the water-trap, and
keep the trap in a vertical position. This will maximize the effectiveness
of the trap and keep liquid from being drawn directly into the analyzer.
• When liquid condensate is seen inside the water trap, empty the trap
before it becomes full.
• When storing the analyzer, empty the water trap and leave it open to
further dry it out.
• Calibrate the analyzer every 6 months to 1 year to assure its accuracy.
• The recommended time required to achieve a stable measurement is a
minimum of 3 minutes.
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4.2
Analyzer Power On & Warm Up
1. Connect the probe and make sure that the analyzer is properly set
up per Section 3.
IMPORTANT! DO NOT insert probe into stack before powering on
the analyzer.
2. Place the probe in an area that contains fresh air. This ensures
that the sensors will be properly zeroed during the warm-up cycle.
3. Power up the analyzer by pressing the PWR button for at least 1
second, or until a single beep is heard. Observe that the analyzer’s firmware version, model and serial
numbers are briefly displayed, followed by the Warm Up screen.
Version: V2.00
Model: 24- 8252
Serial:
NW1060
4. After the 60 second warm-up period is completed, the instrument
will display the Combustion Test HOLD screen.
If, however, any errors are detected during warm-up, the message
“ERRORS DETECTED” will be displayed along with a list of those
errors. In this example, the O2 sensor is missing and the T-Stack
thermocouple is not connected.
Refer to Section 6.7 for a listing and possible remedy for the errors
displayed.
4.3 Fuel Selection
The top line of Combustion Test HOLD screen shows the fuel currently
selected.
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Fyrite INSIGHT
If necessary, change the fuel as follows:
1. Press F2 to access the Setup Menu (per Section 3.7.)
2. Select FUEL. Press ENTER to display the Fuel Selection screen.
3. Select the desired fuel.
4. Press ENTER to view the default value; select Adjust to modify the
default value.
5. Save the selection and return to the Combustion Test HOLD screen
or ESC to cancel and return to the select Fuel Menu. From the Fuel
Menu, press ESC again to return to the Main Menu.
4.4 Sampling Point (See Fig. 4.1)
Forced Air Furnace – When testing atmospheric burner or gravity
vented, forced air heating equipment with a clamshell or sectional heat
exchanger design, test each of the exhaust ports at the top of the heat exchanger. The probe should be inserted back into each of the exhaust ports
to obtain a flue gas sample, before any dilution air is mixed in.
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Hot Water Tank – Domestic hot water tanks with the ‘bell’ shaped draft
diverter on top can be accurately tested by inserting the probe tip directly
into the top of the fire tube below the diverter.
80% Efficiency Fan Assist or Power Vented – Combustion testing of
fan assist or power vented, furnaces/boilers should be done through a hole
drilled in the vent approximately 12 inches above the inducer fan.
90% Efficiency Condensing – Condensing furnaces/boilers can be tested
through a hole drilled in the plastic vent pipe (when allowed by the manufacturer or local authority of jurisdiction) or taken from the exhaust termination.
After testing, the hole should be sealed with high temperature silicon.
Atmospheric or Gravity Vented Boiler – Boilers, which have a ‘bell’
shaped draft diverter directly on top, should be tested directly below the
diverter through a hole drilled in the vent connector.
NOTE: Seal all drill holes upon completion of combustion testing.
33
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Hot Water Tank
Atmospheric Burner
or Gravity Vented
Forced Air
Atmospheric or
Gravity Vented
Boiler
80% Eff. Fan Assist
or Power Vented
Furnace/Boiler
Fig. 4.1
34
90% Eff. Condensing
Furnace/Boiler
Fyrite INSIGHT
4.5 Performing a Combustion Test
Ensure that the following has been completed, and then proceed with the
combustion test as described below:
•Power on the analyzer and allow it to warm up (Section 4.2).
•Select fuel being burned (Section 4.3).
•Inset probe into proper sample location (Section 4.4).
•If necessary, insert optional primary air thermocouple into combustionair stream of burners that use an outside source of ­combustion air.
1. Press the RUN/HOLD button to start the test. The pump will start
running and the word RUN will appear at the top of the Combustion
Test screen.
Sensor Indicators: The following indicators appear in the sensor’s data
field depending on certain conditions:
(∗ ∗ ∗) Sensor that is not calibrated or installed.
(XXX) Sensor overrange
(- - -) The calculated data cannot be displayed because the measured data
necessary to make the calculation is out of range (i.e., oxygen level above
18.8%).
2. Scroll to the T-STK reading. Loosen the thumbscrew on probe stop and
move probe in and out of the stack until the stack’s core temperature
(hot spot) is located as indicated by the highest T-STK reading; then
tighten thumbscrew to prevent further probe movement. Locating the
highest stack temperature is very important for accurate efficiency calculations. Note that the recommended time to achieve a stable reading
is a minimum of 3 minutes.
3. You can now begin burner-service procedures. The analyzer readings
will change quickly to show changes in burner ­performance.
CAUTION: Position the water trap with its gas-flow arrow
pointing upward. Do not allow water condensate above the tip
of the riser tube. The sensors could be damaged if water would
enter the analyzer. Empty the water trap after every combustion test (refer to Section 4.10)
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4. Pressing the RUN/HOLD button freezes all readings, stops the pump and
displays the Combustion-Test HOLD screen. Scroll to view all test values
at the moment the Run/Hold button was pressed. Pressing RUN/HOLD
again restarts the pump and resumes testing.
Display Name
Description of Measurement or Calculation
O2
% Oxygen
CO
ppm Carbon Monoxide
LAMBDA
Excess air
CO2
% Carbon Dioxide
CO2 Max
% CO2 in flue gas assuming perfect combustion
T-STK
Stack Temperature
T-AIR
Primary/Ambient Air Temperature
qA
Stack loss
Eta
Efficiency referenced to the lower heating value
Eff
% Efficiency referenced to the higher heating value
CO/CO2
Carbon Monoxide/Carbon Dioxide ratio
CO(n)
Carbon Monoxide content referenced to % of O2 concentration
AVG SMOKE
Average of 3 manually entered smoke numbers
OIL DERIVE
Manually entered Yes or No
BOILER TEMP
Boiler temperature manually entered
4.6 Making a Draft / Pressure Measurement
The difference in pressure (ΔP) between two areas can be measured by
using the analyzer’s two pressure ports and the Pressure screen. By using
the -ΔP port as the reference, the pressure applied to the +ΔP port will be
displayed on the Pressure screen as the differential pressure between the
two ports. Perform a draft / pressure measurement as follows:
1. Power on the analyzer and allow it to complete its warm-up cycle.
2. Press the MENU (F2) button to access the Main Menu.
3. Use the ▲▼ buttons to select Pressure. Press ENTER to display the
Pressure screen.
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4. Before taking a measurement, the pressure sensor may need to be
re-zeroed if it is not already displaying zero with both pressure
ports open to the atmosphere. If necessary, zero the pressure sensor
as follows:
• Press the ZERO (F2) button.
F1
F2
F3
• Disconnect any hoses connected to the +ΔP and -ΔP ports, and
then press ENTER to zero the pressure sensor
• Reconnect any hoses. When measuring draft, leave the -ΔP
port open to the atmosphere and connect the probe’s draft hose
to the +ΔP port.
5. Do one of the following to measure draft or differential pressure:
• To measure draft, insert the probe into the stack and observe
the draft reading on the Pressure screen.
• To measure differential pressure, connect two sampling hoses to
the +ΔP and -ΔP ports, and place the open end of each hose into
the areas being measured. The differential pressure between
the two areas is now displayed on the Pressure screen. If the
pressure at the +ΔP port is higher than the -ΔP port, the pressure reading will be positive. If it is lower, the reading will be
negative.
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4.7 Temperature Measurement
The difference in temperature between two areas can be measured by using the analyzer’s two temperature channels and the Temperature Screen.
By using the T-Air channel as a reference, the temperature applied to
the T-Stack channel will be displayed on the Temperature Measurement
screen as differential temperature between the two channels.
Perform a differential temperature measurement as follows:
1. Press the MENU (F2) button to display the Main Menu.
2. Use the ▲▼ buttons to scroll to Temperature. Press ENTER to display the Temperature Measurement screen.
3. Install thermocouples in both temperature channel connectors.
4. Before taking a measurement, the temperature channels may need
to be zeroed, if not already displaying zero with both thermocouples
exposed to the same condition. Press ZERO (F2) if necessary.
4.8 Saving Test Data
Up to 100 sets (“snap shots”) of combustion test, pressure, or temperature
data can be saved in memory, which can later be recalled for viewing from
the Memory Directory.
1. First, display the screen that contains the data to be saved. In the
example below, all data associated with the Combustion Test RUN
screen will be saved.
2. Press the Save (F3) button to save the test data in the next available memory location.
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NOTE: When memory is full, the next reading will not be saved
until space is made available by clearing previously saved
data. (Section 4.13)
4.9 Ending a Combustion Test
WARNING! Burn Hazard. Do not touch the probe after removing it from the stack. Allow the probe to cool before
handling (about 5 minutes).
1. Remove probe from the flue-gas stream.
2. Allow the pump to run until all combustion gases are flushed from
the analyzer as indicated by the O2 reading returning to 20.9%.
4.10 Emptying the Water Trap
The Water Trap / Filter Assembly removes stack-gas condensate, and also
prevents soot from contaminating the internal components of the analyzer.
IMPORTANT! Use the Water Trap / Filter Assembly in a vertical position with the gas-flow arrow pointing up.
Empty the water trap chamber after each combustion test, or stop the test
and empty the chamber if the liquid condensate level approaches the tip of
the riser tube.
To empty the trap, first pull apart the two halves of the Water Trap using
a slight twisting motion; empty the water trap chamber, and then reassemble the trap.
After each combustion test, also check the Water Trap’s filter element. If it
looks dirty, replace the filter per Section 6.2.
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4.11 Powering Off the Analyzer & Purging
Power off the analyzer by pressing the PWR button for
at least 2 seconds, or until two beeps are heard. The
unit will count down 5 seconds before shutting down.
Pressing the RUN/HOLD button during this time will
stop the countdown and the analyzer will remain powered on.
If the analyzer was not purged with fresh air then the analyzer may remain
ON with its pump running and display the message “PURGING SENSORS”
as the result of combustion gases still being present inside the analyzer. At
this time the operator should ensure that the probe is removed from the stack,
allowing the analyzer to purge itself with fresh air. The 5-second-shutdown
sequence will not begin until the gas levels inside the analyzer drop below
predeterminded levels.
TIP: Although not recommended, the purging process can be bypassed
by pressing the PWR button a second time.
4.12 Low Battery Alarm
When the batteries are nearly depleted, an empty battery icon appears in
the upper-right corner of the display, and a short beep is sounded every 10
seconds.
After a low battery alarm occurs, the analyzer will continue to operate for
only a few minutes. The operating time that remains depends on many
factors (e.g., pump and backlight powered on or off and the type and condition of the batteries).
4.13 Memory
All saved data can be retrieved for viewing through the Memory option.
To open and view saved test data:
1. Press the MENU (F2) button to access Main Menu.
2. Select Memory to view the Memory Options menu.
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Fyrite INSIGHT
3. Select Memory Directory. Press ENTER to display the data saved in
the Memory Directory.
TIP: In the memory directory, quickly page through the screens by
pressing the PAGE– (F1) and PAGE+ (F3) buttons. Move to the first
or last memory location by pressing the
buttons, respectively.
To Clear Test Data:
1. Press the MENU (F2) button to access Main Menu.
2. Use the ▲▼ buttons to scroll to Memory. Press ENTER to display
the Memory Menu.
3. Select Clear Memory. Select Yes and press ENTER.
A confirmation that the memory has been cleared will be briefly displayed.
4.13.1 Averaging Stored Test Data
The Fyrite Insight will provide data averages for 3 consecutive combustion records that are also printable. The combustion tests must first be
stored in program memory (After running a test, press the F3 key to save
the results).
41
Fyrite INSIGHT
1. From the Main Menu, select Memory. The Memory Options screen
will be displayed.
2. Select Print Average.
3. The saved tests will be displayed, with the first 3 tests highlighted.
Select the 3 combustion tests to be averaged from the list by using
the ▲▼ buttons.
4. Press the ENT key. The average test results will be displayed.
All 3 tests that are selected must be combustion tests. If any other kind
of test is selected with combustion tests, as in the example below, an error
message, “Inconsistent data” will be displayed. An average will not be
calculated.
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4.14 Printing Test Data
Combustion, pressure, smoke number or temperature data that is currently
being displayed can be sent to a printer using IrDA protocol as described
below.
Data that is stored in memory can also be p
­ rinted by first displaying the
stored test data as described in Section 4.13.
In addition to printing combustion, pressure, and temperature data, the
contents of any screen that shows the label “PRINT” above the F1 button
can be printed. For example, the information shown in the DIAGNOSTIC
screen can be printed.
1. Power up the printer. Refer to the printer’s instruction manual for
detailed operating information. If not previously done, select the following for the p
­ rinter for:
• 8 bit
• No parity
• 9600 baud
• IrDA is set to IrDASIR
• DTR handshaking
BACHARACH, INC.
Fyrite Insight
SN: 1234-5678
Time: 10:28:38
Date: 09/01/09
2. Align the printer with
the top of the analyzer.
Fuel
NGAS
3. Press the PRINT (F1)
button to begin printing.
F1
F2
F3
RUN
HOLD
ESC
PWR
O2
4.0 %
CO
11 ppm
LAMBDA 1.23 %
CO2
9.5 %
CO2 Max
11.8 %
o
T-STK
190 C
o
T-AIR
22.3 C
qA 8.0 %
Eta
92.0%
Eff
82.4%
CO/CO2
0.0001%
CO(O)
13 ppm
AVG SMOKE ***
OIL DERIVE
***
o
BOILER TEMP *** C
Comments:
Fig. 4.2
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4.15 Fyrite ® User Software
For information on the installation of the Fyrite® User Software, refer to
the installation document (provided in .PDF format) on the software disk.
The Fyrite® User Software installation manual may also be downloaded
from the Fyrite® Insight page of the Bacharach website (www.MyBacharach.com). Refer to manual 0024-9465. Minimum computer requirements
for installation and use of the Fyrite® User Software are shown below.
Fyrite® User Software Minimum Requirements
Operating System Windows XP or higher
Drive
CD ROM Drive
Access Port
USB port (USB 1.1, 2.0, or 3.0)
Hard Drive Space
Software: 205 MB for the Fyrite User Software
Date:
Add 350 KB for each downloaded file
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5.0 CALIBRATION & MAINTENANCE
IMPORTANT: Before performing any calibration procedure,
ensure that fresh batteries are installed or use the optional
AC power adapter. Also, ensure that the analyzer is at room
temperature and will be sampling fresh air when powered
ON.
IMPORTANT: To maintain accuracy as listed in the Technical Characteristics Section of this manual, the standards
used must be at least four times as accurate as the stated
accuracy of the Fyrite® INSIGHT.
5.1 B-Smart™ Sensors
The Fyrite® INSIGHT utilizes Bacharach’s new B-Smart™ Sensor technology for its CO sensor. The B-Smart™ sensor is marked with a 10-digit
calibration code that can be entered in the instrument’s memory via the
keypad, or with Fyrite user software.
Benefits of B-Smart™ Sensors:
• New sensors can be installed without applying gas for calibration.
• Sensors can be pre-calibrated and installed when needed.
• Sensors can be moved from one analyzer to another.
The B-Smart™ sensors should be calibrated by an authorized Bacharach
Service Center every 6 to 12 months to assure that the analyzer continues to meet its published accuracy specifications. The B-Smart™ sensors,
however, can be calibrated in the field if your facility has the necessary
equipment and qualified personnel to perform the procedures described in
the following sections of this instruction manual.
5.2 Starting a Calibration
Start any calibration by performing the following:
1. With the analyzer power off, place the unit in fresh, ambient air;
then power on the analyzer.
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Fyrite INSIGHT
2. Allow the analyzer to cycle through its 60 second warm-up period.
During warm-up, the analyzer’s operation is checked and the sensors are set to the following ambient conditions:
• Oxygen sensor spanned to 20.9%
• CO sensor zeroed
• Pressure sensor zeroed
Any errors detected during warm-up will be listed on the display
immediately following warm-up, as displayed below.
Correct any errors before proceeding. Refer to Section 6.7 for a
list of error messages and their meanings.
3. Press the MENU (F2) button to access the Main Menu.
4. Use the ▲▼ buttons to select Calibration. Press ENTER to display the Calibration Password screen.
5. Before calibration can begin a 4-place numeric password must be
entered. Use the ▲▼ and ◄► buttons to enter the password.
(Note that the default password is 1111)
6. Press the ENTER button to accept the password. If the correct
password was entered, the Calibration Menu will be displayed.
7. Use the ▲▼ buttons to select the desired sensor channel to be
calibrated, and then perform the calibration procedure for that
sensor as described in the following sections.
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5.3 B-Smart™ Sensor Replacement & Calibration
To replace a B-Smart™ sensor and calibrate do the following:
1. Enter the CALIBRATION MENU per Section 5.2.
2. Use the ▲▼ buttons to select B-SMART. Press ENTER to display
the B-Smart code screen.
3. Use the ▲▼ buttons to enter the 10 digit alphanumeric code supplied with the B-Smart sensor. Use the ◄► buttons to move the
cursor across the screen. Press ENTER.
NOTE: If the correct code was entered, the analyzer accepts it and
returns to the CALIBRATION MENU. If an incorrect
code was entered, the screen will display “Invalid Code”.
Check to make sure the correct code has been entered. If
problem persists, contact your nearest Bacharach Service
Provider.
Bacharach also offers a convenient Exchange Program that allows the
customer to regularly send in old sensors and, as scheduled, receive new
replacements that are already calibrated and that include a code that can
be entered into the analyzer for a quick, convenient setup. Contact Bacharach customer service for more details about this program.
5.4 Pressure Sensor Calibration
This procedure calibrates the pressure sensor to a known pressure value.
Materials Required:
• Bellows
• Manometer
- Range: ± 20 mB (± 8 inwc)
- Accuracy: ± 0.025 mB (± 0.01 inwc)
47
Fyrite INSIGHT
Procedure:
NOTE: The unit-of-measure for pressure is selected per Section 3.7.2. In
the following procedure mB is selected, but note that any unit-ofmeasure can be used for calibration purposes.
Figure 5-1 Pressure Sensor Calibration Equipment
1. Assemble the pressure sensor calibration equipment as shown in Figure 5.1, but DO NOT connect the analyzer to the calibration equipment at this time.
2. If not already done, power on the analyzer and display the Calibration List per Section 5.2.
3. Use the ▲▼ buttons to select Pressure. Press ENTER to display the
Calibrate Pressure screen.
“Measured” is the pressure value currently detected by the pressure
sensor. “Applied” is a known value of pressure that will be applied
for calibration purposes.
4. With both the -ΔP and +ΔP ports open to the atmosphere, observe
that the current Measured pressure reading should be 0.00 ± 0.01
48
Fyrite INSIGHT
mB. If necessary, zero the pressure sensor per Section 4.6 then
repeat steps 2 through 4.
5. Connect the hose from the manometer to the +ΔP port and apply a
negative pressure to this port by adjusting the bellows for a manometer reading of -10.00 mB.
6. Use the ▲▼ buttons to enter an Applied value that exactly equals
the manometer reading.
The calibration range is from -15 to -5 mB (-6 to -2 inwc). An
attempt to calibrate outside this range will cause the message
“Applied Value High” (or Low) to appear at the bottom of the screen.
7. Wait until the Measured reading stabilizes, and then press ENTER
to calibrate the pressure sensor’s Measured value to that of the Applied value. The message, “Good Calibration” should briefly appear,
followed by the Calibration List screen.
8. Remove calibration equipment.
Resetting the Calibration Pressure Gain
NOTE: This feature resets the calibration to the default value and
should be done under the direction of an authorized Bacharach
service function. Reset is available in all calibration screens.
5.5 T-Stack Calibration
This procedure first zeroes and then spans the stack-temperature channel
to known temperature values.
The use of an electronic thermocouple simulator is the preferred method
of producing the desired calibration temperatures. Alternatively, ice and
boiling water baths can be used.
Materials Required:
• Thermocouple simulator (K-type)
49
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50
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- Range: 0 to 300 °C
- Accuracy: ± 0.3 °C
• (Alternatively) ice-water, boiling water, thermometer
TS-Zero Procedure:
1. Set the thermocouple simulator to room temperature and plug its
output into the T-STACK connector located at the bottom of the
analyzer.
Alternatively: Plug the probe’s thermocouple into the T-STACK connector located at the bottom of the analyzer. DO NOT attach the
probe’s gas hose to the analyzer’s GAS port; otherwise water
will be drawn into the analyzer!
2. If not already done, power up the analyzer and display the CALIBRATION LIST screen per Section 5.2.
3. Use the ▲▼ buttons to highlight T-Stack, and then press ENTER to
display the CALIBRATE TS-ZERO screen.
1
“Measured” is the current temperature reading, while “Applied” is a
known temperature that will be applied for calibration purposes.
4. Set thermocouple simulator to 0 °C (32 °F), and then use the
and
buttons to enter an Applied value that exactly equals the setting
of the simulator.
Alternatively: Submerge probe tip into an ice-water bath with a thermometer, wait several minutes, and then use the
and
buttons
to enter an Applied value that exactly equals the thermometer reading.
The calibration range is from 0 to 5 °C (32 to 41 °F ). An attempt to
calibrate outside this range will cause the message “Applied Value
High” (or Low) to appear at the bottom of the screen.
5. Wait until the Measured reading stabilizes, and then press ENTER
to calibrate the TS-Zero Measured value to that of the Applied
51
Fyrite INSIGHT
­value.
The message “Good Calibration” should briefly appear, followed by
the Calibrate TS-Span screen.
TS-Span Procedure:
6. Set thermocouple simulator to 300 °C (572 °F), and then use the
and
buttons to enter an Applied value that exactly equals the
setting of the simulator.
295
300
Alternatively: Submerge probe tip into a container of boiling water
with a thermometer, wait several minutes, and then use the
and
buttons to enter an Applied value that exactly equals the thermometer reading.
The calibration range is from 80 to 330 °C (175 to 625 °F). An attempt to calibrate outside this range will cause the message “Applied
Value High” (or Low) to appear at the bottom of the screen.
7. Wait until the Measured reading stabilizes, and then press ENTER to
calibrate the TS-Span Measured value to that of the Applied v
­ alue.
The message “Good Calibration” should briefly appear, followed by
the re-display of the Calibration List screen.
5.6 T-Air Calibration
This procedure first zeros and then spans the ambient-temperature channel to known temperature values.
The use of an electronic thermocouple simulator is the preferred method of
producing the desired calibration temperatures. Alternatively, ice and boil-
52
Fyrite INSIGHT
ing water baths can be used.
Material Required:
• Thermocouple simulator (K-type)
- Range: 0 to 300 °C
- Accuracy: ±0.3 °C
• (Alternatively) Ice-water, boiling water, thermometer
TA-Zero Procedure:
1. Set thermocouple simulator to room temperature and plug its output
into the T-AIR connector located at the bottom of the analyzer.
Alternatively: Plug the probe’s thermocouple into the T-AIR connector
located at the bottom of the analyzer. DO NOT attach the probe’s
gas hose to the analyzer’s GAS port; otherwise water will be
drawn into the analyzer!
2. If not already done, power up the analyzer and display the CALIBRATION LIST screen per Section 5.2.
3. Use the
buttons to highlight T-Air, and then press ENTER to
display the Calibrate TA-Zero screen.
0.4
“Measured” is the current temperature reading, while “Applied” is a
known temperature that will be applied for calibration purposes.
4. Set thermocouple simulator to 0 °C (32 °F), and then use the
and
buttons to enter an Applied value that exactly equals the
setting of the simulator.
Alternatively: Submerge probe tip into an ice-water bath with a thermometer, wait several minutes, and then use the
and
buttons to enter an Applied value that exactly equals the thermometer
reading.
The calibration range is from 0 to 5 °C (32 to 41 °F). An attempt to
calibrate outside this range will cause the message “Applied Value
High” (or Low) to appear at the bottom of the screen.
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5. Wait until the Measured reading stabilizes, and then press ENTER
to calibrate the TA-Zero Measured value to that of the Applied
­value. The message “Good Calibration” should briefly appear, followed by the Calibrate TA-Span screen.
TA-Span Procedure:
6. Set thermocouple simulator to 100 °C (212 °F), and then use the
and
buttons to enter an Applied value that exactly equals the
setting of the simulator.
Calibrate
Calibrate TA-Span
TA-Span
o
Measured:
Measured: 211.
981
Measured:
211.
1 C°F
°F
Applied:
Applied: 212.0
100 oC °F
Applied:
212.0
°F
Press
ENT
Press ENT
Press
ENT
Print
Print
S1
S1
S2
S2
S3
S3
Alternatively: Submerge probe tip into a container of boiling water
with a thermometer, wait several minutes, and then use the
and
buttons to enter an Applied value that exactly equals the thermometer reading.
The calibration range is from 90 to 110 °C (194 to 230 °F). An attempt to calibrate outside this range will cause the message “Bad
Calibration Wrong CAL Entry” to appear in the following step.
7. Wait until the Measured reading stabilizes, and then press ENTER
to calibrate the TA-Span Measured value to that of the Applied
­value. The message “Good Calibration” should briefly appear, followed by the re-display of the Calibration List screen.
5.7 CO Sensor Calibration
Material required:
• Calibration kit, P/N 0024-7059
• Gas cylinder: 500 ppm CO in air, P/N 0024-0492
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Fyrite INSIGHT
To improve the accuracy of the CO reading, we suggest that if the analyzer
will be primarily used for flue gas testing, then calibrate using 500 ppm
CO. If the analyzer, however, will be primarily used for ambient testing,
then calibrate using 100 ppm CO.
Procedure:
1. If not already done, power up the analyzer and display the Calibration List screen per Section 5.2.
2. Use the
buttons to highlight CO, and then press ENTER to display the Calibrate CO screen.
4
“Measured” is the current CO reading, while “Applied” is a known
CO level that will be applied for calibration purposes.
3. Attach a 500 ppm CO cylinder to the regulator of the calibration
fixture.
4. Use the
and
buttons to enter an Applied value that exactly
equals the concentration stamped on the CO cylinder.
The calibration range is from 20 to 1,000 ppm. An attempt to
55
Fyrite INSIGHT
®
Fyrite INSIGHT Components
2
3
1
5
To gas
fitting
J9
(Pump)
To O2
To O2
sensor
cap
J11
(Battery)
To gas
4
Fig. 6.1
Front View
1. O2 Sensor
4. Sample Pump
2. CO Sensor
5. LCD Screen
Side View
3. CO Sensor Base
®
Fyrite INSIGHT End Plate Connectors
6. AC Power Adapter Jack (Power)
7. Sample Gas Thermocouple Connector
(T-Stack)
Front
7
6
8
9
8. Primary Air Thermocouple (T-Air)
9. USB Connector
10. Differential Pressure Hose
(Optional)
11. Draft Hose
12. Sample Gas Hose
10
11
12
Back
Fig. 6.2
56
Fyrite INSIGHT
calibrate outside this range will cause the message “Applied
Value High” (or Low) to appear at the bottom of the screen.
5. Wait until the Measured reading stabilizes and then press ENTER to
calibrate the CO Measured value to that of the Applied ­value. The
message “Good Calibration” should briefly appear.
If the sensor’s output is low, but still usable, the message “Good
Calibration WARNING Low Sensor” will appear. The sensor
will now be marked as Low in the Diagnostics screen.
If the sensor’s output is too low to be used, the message “Bad
Calibration Sensor End of Life, Entry Not Saved” will appear.
The sensor will now be marked as BAD in the Diagnostics
screen.
6. Turn off the gas and remove the CO cylinder.
6.0 Maintenance
6.1 Fyrite® INSIGHT Disassembly
The following section describes how to disassemble the Fyrite INSIGHT to
perform necessary periodic maintenance. (See Figure 6.1 for diagram.)
Tools Required:
• Medium Phillips screwdriver
Procedure:
1. Unplug all thermocouples from ­bottom of analyzer.
2. Remove battery cover and then remove batteries.
3. Remove sensor caps, disconnect tubing, and then unplug all sensors.
4. Place the analyzer face down on a padded work surface. Remove the
unit’s four rear-case screws with a medium Phillips screwdriver,.
5. Lift rear case from analyzer and set aside.
6. Unplug electrical connector J11 from printed circuit board.
57
Fyrite INSIGHT
7. Lift printed circuit board from analyzer.
6.2 Water Trap / Filter
6.2.1 Emptying the Water Trap Chamber
The water trap chamber should be emptied after every test, or when the
water condensate approaches the tip of the riser tube.
1. Remove water trap chamber per Figure 6.3.
2. Pour out liquid condensate, and then reassemble trap.
6.2.2 Replacing the Filter Element
Replace the filter element when it becomes visibly dirty or becomes saturated with water.
Material Required: • Filter element, P/N 0007-1644
• Small flat blade screwdriver
1. Remove water trap chamber per Figure 6.3.
2. Pry apart filter chamber using a small flat-blade screw
driver. Remove and discard old filter.
3. Install new filter and reassemble filter chamber, making sure that surfaces “A” and “B” contact each other.
4. Reassemble trap.
FILTER
CHAMBER
Pull apart
using a
twisting
motion.
Pry apart
filter chamber
using a small
flat-blade
screwdriver
inserted into
notch
WATER
TRAP
CHAMBER
Fig. 6.3
58
When reassembling filter chamber,
make sure surfaces
“A” and “B” contact
each other
“A”
FILTER
ELEMENT
DO NOT
rock back
and forth!
“B”
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6.3 O2 & CO Sensor Replacement
O2
Sensor
CO
Sensor
Pry tab
upward to
remove the
battery door
from the unit.
Fyrite® Rear Panel
Fig. 6.4
6.3.1 O2 Sensor
Note: The O2 sensor life is approximately 2 years and the CO sensor
life is greater than 3 years.
Material Required:
• O2 Sensor (P/N 0024-0788)
Procedure:
1. After battery door is removed, remove connector tubing from both sensors.
2. Pull O2 sensor from its socket and remove the O2 cap.
3. Properly dispose of the old sensor. Engage the bayonet on the new
sensor within the slot on the cap’s side and twist to secure the cap and
sensor together.
59
Fyrite INSIGHT
Bayonet
O2 Cap
Nub
Sensor
Fig. 6.5
4. Install the cap and sensor unit by
• Aligning the ribs on the sides of the sensor with the corresponding
shape in the base.
• Inserting the pins into the connectors in the base.
5. Reattach tubing.
6.3.2 CO Sensor
Material Required:
• CO Sensor (P/N 0024-7265) or B-Smart sensor (P/N 0024-1467)
Procedure:
1. After battery door is removed, remove the connector tubing from the
CO sensor.
2. Remove CO cap by twisting counter clockwise. Gently pull CO sensor out of its socket.
CO Cap
Sensor
Printed Circuit Board
60
Fig. 6.6
Fyrite INSIGHT
3. Properly dispose of the old CO sensor.
4. Plug the new CO sensor into its socket.
5. Install the CO cap by aligning the arrow on the cap with the
“OPEN” marker, then twisting to the “CLOSED” marker. Reattach
tubing.
6.4 Thermocouple Replacement
Replace the probe’s thermocouple as follows:
Replacement kit contains a thermocouple assembly, two O-rings, and two
wire-splice connectors.
Tools Required:
•Small flat blade screwdriver
•Wire cutter
•Wire stripper
•Slip joint pliers
Procedure:
1. Gain access to the thermocouple connections by first removing three
screws from probe handle, and then separating the two handle
pieces.
2. Cut wires attached to old crimp connectors, leaving behind as much
of the probe’s thermocouple-connector wire as possible
Probe Handle
Screws
Fig. 6.7
3. Pull old thermocouple from probe body and discard.
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4. The new thermocouple has been coiled for shipping purposes.
Straighten the thermocouple using your thumb and index finger.
5. If not already done, install supplied O-Rings onto thermocouple.
6. Insert thermocouple into probe body until it “bottoms out.”
7. Strip 1/4 inch of insulation from each of the probe’s thermocouple
­connector wires.
IMPORTANT: In Step 8, the thermocouple wires must first be twisted
together and then crimped.
8. Twist both red thermocouple wires together; insert them into the
supplied wire-splice connector; and then crimp the connector using
a pair of pliers. Repeat this step for the yellow thermocouple wires.
9. Reassemble the probe handle, being careful not to pinch the thermocouple wires between the handle pieces. In addition, ensure that
the end of the thermocouple is in front of the rib molded into the
bottom handle piece; otherwise, the handle pieces will not fit tightly
together.
6.5 Gas Pump Replacement
Ordering Replacement Parts:
Two replacement pumps are available based on the revision of the printed
circuit board (PCB) inside your Insight. Proper PCB version identification
ensures that you order and receive the correct replacement pump. Use the
serial number of your analyzer to determine which PCB revision it has.
1. Locate the serial number on the back of your Insight analyzer.
2. Compare your serial number with transition serial number RU1025. If
your serial number is RU1025 or newer, you have a Revision 1 PCB. If
your serial number is older than RU1025, you have a Revision 0 PCB.
NOTE: Bacharach serial numbers contain a mix of alphabetic and numeric characters. The first two most significant positions are represented
by sequential characters A-Z (where “A” is earlier than “Z”). The last four
least significant positions are each represented by digits 0-9 (where “0” is
earlier than “9”). For example, serial number AZ9999 is older (i.e., was
assigned earlier) than serial number ZA0000.
NOTE: During certain Insight repairs (for example, the replacement
62
Fyrite INSIGHT
of a battery wiring harness), service personnel may also need to replace
the pump wiring harness. This is performed only by Bacharach service
personnel. In such cases, wiring harness part numbers are listed in the
following table for service personnel reference. For standard pump replacement orders, however, customers must use the combination pump/harness
part number. Refer to the table below.
Item
PCB Rev 0
PCB Rev 1
Serial # (Back of
Instrument)
< RU1025
(= Rev 0)
≥ RU1025
(= Rev 1)
PCB Label (To
Confirm Rev #)
0024-1450
0 xxxxxxxx
0024-1450
1 xxxxxxxx
Order P/N: 0024-3049
Order P/N: 0024-3073
P/N: 0024-1410
P/N: 0024-1521
Pump/Harness
Part Number
Connector
Style on Pump
Wiring Harness
(Colors May Vary)
PCB Header Style
Wiring Harness
Only (Reference
P/N for Service
Personnel Only)
Parts & Tools Required:
• Replacement pump (P/N 0024-3049 or P/N 0024-3073)
• Medium phillips screwdriver
Procedure:
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1. Gain access to the gas pump by removing the rear case. Refer to Section 6.1.
2. Disconnect J9 (pump) and J11 (Battery) connectors.
3. Lift the circuit board out of the unit.
4. Remove the screw that secures the pump to the board in order to
separate the pump from the board.
5. Remove tubing from pump.
6. Install new pump by reversing this procedure.
6.6 Cleaning the Probe
The probe tube and gas-sample hose will become dirty under normal use.
Note that the water trap’s filter element should prevent soot from reaching
the analyzer’s internal components. If the probe is not kept clean, it could
become clogged and restrict the flow of gas into the analyzer, resulting in
incorrect combustion test readings and calculations.
NOTE: An analyzer that is used to test natural gas furnaces
normally requires less frequent cleaning than an analyzer used for testing coal or oil fired furnaces.
Equipment Required:
•
•
•
•
Alcohol
Aerosol can of automotive carburetor cleaner
Clean rag
Source of compressed air (optional)
Procedure:
1. Remove gas-sample hose from top of water trap.
CAUTION: Carburetor cleaner attacks plastic components! Take precautions not to spray cleaner onto the
probe handle or analyzer.
2. Insert the plastic-spray tube of the carburetor cleaner into the gassample hose, and then liberally spray carburetor cleaner through the
hose and out the probe tube.
3. After spraying, remove all the residual cleaner by repeatedly flush64
Fyrite INSIGHT
ing the gas hose and probe tube with alcohol.
4. Wipe off the surfaces of the probe and tubing with a clean rag.
5. Allow the parts to dry completely. If available, blow compressed air
through the probe to expedite the drying process.
6. Reconnect gas-sample hose to top of water trap.
6.7 Error Messages
Bad Sensor - O2 sensor is too low and can not be calibrated in the instrument and needs replaced.
Low Battery - Battery voltage is low. Replace the batteries.
Low Sensor- O2 or CO sensor outputs were low but still usable. Sensor(s)
may need to be replaced in the near future. Message will indicate which
sensor(s) were in warning.
O2 Sensor Missing - The O2 sensor is not installed.
T-STK Disconnected - The probe thermocouple is not connected to the
analyzer’s T-Stack connector. Plug the probe thermocouple plug into the
T-Stack connector at the bottom of the instrument.
Warmup Sensor Error • CO sensor was not zeroed at warmup because of high output. Run
instrument on fresh air then restart instrument to re-zero sensor. If
message persists, CO sensor may need to be replaced.
• Stack or Air temperature channel is measuring temperature outside
the range of -20 to 100 ˚C at startup. Make sure that the Stack and
Air thermocouples are sampling ambient room air within the temperature range at startup.
• Pressure sensor is measuring pressure outside the range of ± 7.5 mB
at startup. Ensure that the analyzer is sampling atmospheric pressure and restart the instrument.
• The analyzer was turned on with the probe sampling flue gas. Move
the probe to fresh air and restart the instrument.
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• Message will indicate which channel is in error.
XXXX - Occurs in the number fields of sensors that have achieved overrange condition.
**** - Occurs in the number fields of sensors and the calculated values
that depend on the sensors that were in error coming out or warmup.
- - - - Occurs in the number fields of calculated values when Oxygen is
above 18.8%.
6.8 Diagnostics Screen
The DIAGNOSTICS menu provides information regarding the operation of
the analyzer. Information includes the following:
Time Meters - Displays the run time of the analyzer and sample pump in
hours of operation.
Main Diagnostics - Lists the current status of the Stack and Air Thermo-
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couple channels, Reference Temperature channel, Pressure channel, CO
channel, O2 channel and Battery.
O2 Sensor Life - Displays the approximate remaining life of the Oxygen
sensor.
Fresh Air Diagnostics - Fresh air diagnostics will cycle the instrument
through the 60 second warm-up to check on the status of the sensors. The
probe must be in fresh air to perform a valid check.
Access the Diagnostic menu as follows:
1. Display the Main Menu by pressing the MENU (F2) button. If necessary,
press ESC until Menu appears above F2.
2. Use the ▲▼ buttons to highlight Diagnostics and then press ENT to
display the Diagnostic Menu.
3. Use the ▲▼ buttons to highlight the desired diagnostic topic and then
press ENT to display the information under that topic.
4. Press the ESC key to exit back to the Diagnostic Menu or the MENU (F2)
key to exit back to the Main Menu.
6.9 Status Screen
The Status Screen provides a quick reference to key items when troubleshooting:
•
•
•
•
•
Version
Built
ADC Version
Boot Version
Model
• SN
Access the Status menu as follows:
1. Display the Main Menu by pressing the MENU (F2) button.
2. Use the ▲▼ buttons to highlight Status and then press ENT to display
the Device Status screen.
3. Press the ESC key to exit back to the Main Menu.
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7.0 PARTS & SERVICE
7.1 Replacement Parts
Description
Part Number
Battery / Sensor Cover
0024-1453
B-Smart CO Sensor
0024-1467
Carry Case
0024-0865
Connector Plate Assembly
0024-1483
CO Sensor
0024-7265
CO Sensor Cover Assembly
0024-1484
Draft Connector
0024-0878
Filter (pkg of 3), Water Trap
0007-1644
Gas Connector
0024-0877
O-Ring Kit (2 sets)
0024-1471
O2 Sensor
0024-0788
O2 Sensor Cover
0024-1421
PC Software
0024-1470
Probe & Hose Assembly
0024-3053
Probe Stop
0019-3037
Replacement Pump
0024-3049 or 0024-3073
(see Section 6.5)
Thermocouple Replacement (30.48 cm)
0024-8390
USB cable
0104-4032
Water Trap
0019-3265
NOx Filter
0024-1505
7.2 Accessories
68
Description
Part Number
AC Adapter
0024-1254
Boot
0024-1461
Calibration Gas, 100 ppm CO
0051-1994
Calibration Gas, 500 ppm CO
0024-0492
Fyrite INSIGHT
Calibration Kit
0024-7059
Differential Pressure & Temperature Kit
0024-8242
IrDA Printer
0024-1400
Printer Paper (pkg of 1)
0006-8733
Printer Paper (pkg of 5)
0024-1310
Smoke Kit
0021-7006
Thermocouple, 2.5 cm
0104-1798
Thermocouple, 3.0 m
0104-1797
7.3 Service Centers
Replacement parts and service can be obtained by contacting one of the following Bacharach Service Centers:
United States
621 Hunt Valley Circle
New Kensington, PA 15068
Phone: 724-334-5051
Fax: 724-334-5723
Email: [email protected]
Canada
Bacharach of Canada, Inc.
20 Amber St. Unit #7
Markham, Ontario L3R 5P4
Canada
Phone: 905-470-8985
Fax: 905-470-8963
Email: [email protected]
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Fyrite INSIGHT
8.0 DECLARATION OF CONFORMITY
DECLARATION OF CONFORMITY
The manufacturer of the products Bacharach, Inc.
covered by this declaration: 621 Hunt Valley Circle
New Kensington, PA 15068
Year conformity is declared: 2010
Product(s): Combustion Analyzer
Model(s): Fyrite INSIGHT (Siegert)
The undersigned hereby declares that the above referenced products are in conformity with the provisions of
the following standard(s) and is in accordance with the following directive(s).
Standard(s):
EN 50379-1 Part 1
General Requirements
and Test Methods
Specifications for Portable Electrical Apparatus Designed to
Measure Combustion Flue Gas Parameters of Heating
Appliances
EN 50379-3 Part 3
Performance
Requirements
Performance Requirements for Apparatus Used in NonStatutory Servicing of Gas-Fired Heating Appliances
EN 50270:2006
Electromagnetic
Compatibility
Electrical Apparatus for the Detection and Measurement of
Combustible Gases, Toxic Gases, or Oxygen
Directive(s):
2004/108/EC
EMC Directive
Signature:
Name:
Doug Keeports
Title:
VP of Product Development
Date:
18 October 2010
The technical documentation file required by this directive is maintained at the corporate headquarters of Bacharach, Inc.
70
Fyrite INSIGHT
Appendix A- Formulas & Tables
CO max (20.9 – O %)
CO =
2
2
20.9
2
qA = (TA – TL) x (
A2
+B)
20.9 – O
2
20.9
20.9 – O2
λ (Excess Air) =
Eta = (100% – qA) + [Kf, if TA < (T0 – 1.2 x O )]
2
Efficiency = Eta – Kf
CO Air Free (Undilute) = CO x λ
–
COppm x 10 6
CO/CO =
–
CO % x 10 2
2
2
Where:
O2 =
TA =
TL =
CO =
CO2 =
qA =
λ
=
Measured Oxygen in percent
Measured stack temperature in oC
Measured combustion air temperature in oC
Measured carbon monoxide level in ppm
Calculated carbon dioxide level in percent
Calculated stack loss in percent
Calculated LAMBDA
A2, B, CO2 max, T0, and Kf are constants (see table below):
Fuel
A2
B
Natural Gas
0.66
0.009
Propane
0.63
Oil #2
LEG
CO2 Max
T0
Kf
11.8
58 °C
9.6%
0.008
13.8
54 °C
7.6%
0.68
0.007
15.4
51 °C
5.3%
0.63
0.011
13.1
61 °C
10.3%
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